A fitting including a tubular extension, flange with apertures, and interface there between is fused with surrounding cured in place pipe and subsequently connected with an adjoining fitting, to connect two segments of pipe in a pipeline. The tubular extension is sized and shaped to mate with the host pipe with which it is associated, and the flange is sized, shaped, and has an aperture pattern that corresponds with the fitting to which it will be attached.
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2. A pipe repair system including a cipp chemically and structurally bonded with a fitting, said cipp including:
A. A needle punched tubular substrate including a plurality of integrated thermoplastic fibers, said tubular substrate constructed of multiple overlapping layers that aren't attached one to another;
B. A bladder surrounding said tubular substrate; and
C. A film surrounding said tubular substrate, and wherein said cipp and said fitting are constructed of substantially identical materials.
3. A method of repairing a pipe including the steps of:
A. Inserting an uncured cipp into a pipe segment having a compromised portion, said cipp including a needle punched tubular substrate including a plurality of integrated thermoplastic fibers, said tubular substrate constructed of multiple overlapping layers that aren't attached one to another; a bladder surrounding said tubular substrate; and a film surrounding said tubular substrate;
B. Curing said cipp;
C. Positioning at least one fitting onto a distal end of said pipe segment;
D. Curing said fitting by blowing air at approximately 380-470° F., at a pressure of approximately 5-20 psi, for approximately 5 to 90 minutes; and;
E. Connecting said fitting to an adjacent corresponding fitting.
1. An uncured fitting for use with a cipp having needle punched tubular substrate including a plurality of integrated thermoplastic fibers, said tubular substrate constructed of multiple overlapping layers that aren't attached one to another, said uncured fitting comprised of a fitting substrate having a tubular extension joined with a flange at an interface, said fitting substrate constructed of plurality of carbon fibers, aramid fibers and thermoplastic fibers needle punched together, wherein said fitting substrate is curable upon the application of blown air at approximately 380-470° F., at a pressure of approximately 5-20 psi, for approximately 5 to 90 minutes, and wherein said tubular substrate and said fitting substrate are chemically and structurally bonded upon curing.
4. The method of
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This application claims the priority of U.S. Provisional Patent Application Ser. No. 62/630,873, entitled PIPE FITTINGS HAVING INTEGRATED THERMOPLASTIC WITH IMPROVED HELT-FLOW CHARACTERISTICS FOR CURED IN PLACE PIPE SYSTEMS AND ASSOCIATED METHOD OF USE, which was filed Feb. 15, 2018. The aforementioned provisional application is hereby incorporated by reference in its entirety.
The present invention relates to repairing and reinforcing segments of pipe in pipelines, and more specifically, to cured in place pipe fittings for use with cured in place pipe systems.
Pressure pipe systems are typically constructed of multiple pipe segments with each pipe segment having a pipe fitting at each terminal end. The pipe segments are connected end to end by joining and bolting pipe fittings one to another. With time and usage these segments become critically deteriorated or damaged and require repair and/or reinforcement. Replacing pipe segments can be achieved in a variety of ways including digging to access the pipe, removal of the old pipe, putting in new pipe, and tying new pipe into existing pipeline; and various trenchless pipe repair methods. Of the trenchless pipe repair systems, Cured In Place Pipe (“CIPP”) technologies have shown great promise.
CIPP technology generally involves lining the inside of a damaged or deteriorated host pipe with a flexible substrate that has been impregnated with a liquid curing agent such as epoxy, then curing the wetted substrate with heat, pressure, UV, or the like.
An improved CIPP system developed by the inventor(s) of the current application is disclosed in U.S. patent application Ser. No. 15/614,852, filed Jun. 6, 2017, entitled CURED IN PLACE PIPE SYSTEM HAVING INTEGRATED THERMOPLASTIC WITH IMPROVED MELT-FLOW CHARACTERISTICS. This application claims the benefit of U.S. Provisional Patent Application 62/357,796, filed on Jul. 1, 2016. Both of these references are hereby incorporated by reference in their entirety.
The aforementioned improved CIPP system includes a flexible tubular substrate comprised of fibers of carbon, aramid and thermoplastic which have been needle punched together and formed in a tube of overlapping layers that can circumferentially expand to accommodate the size and shape of the host pipe. An outer plastic film encapsulates the tubular structure to protect it from contamination by the host pipe during installation. The thermoplastic has a melt/flow point of approximately 300-342° F., a cure point of approximately 330-370° F., and a bonding point of approximately 372-412° F. at approximately 5-20 psi.
In use, the uncured CIPP system is introduced into the host pipe, an internal bladder is pumped with hot air, the tubular substrate's thermoplastic melts, carbon and aramid fibers bond, and the thermoplastic cures. After curing, the bladder is removed, and ends of the cured lining system are cut. The result is a repaired and/or reinforced host pipe.
One issue with CIPP technologies, both conventional and the aforementioned improvement, is the reconnection of a CIPP enhanced host pipe to the existing pipes in a pipeline. More specifically, CIPP repair of pressure pipes typically requires rehabilitation of the entire pipe including fittings, then the possibility of cutting off the fittings, then installation of new fittings, after the insertion of CIPP enhanced segment back into the pipeline. Replacement fittings are difficult to install, and their failure rate is high.
As can be seen, there is a need for improved fittings for use with CIPP enhanced pipe. It is desirable that these fittings are easy to install, irreversibly bond with the host pipe, are strong and resistant to deterioration, cause little resistance to flow, and don't leak. Methods for installing and using these improved fittings are also needed.
A pipe fitting is cured in situ, thereby fusing with surrounding cured in place pipe. The fitting is subsequently connected with an adjoining fitting, to connect two segments of pipe in a pipeline.
The fitting generally includes a tubular extension, a flange that defines a plurality of apertures, and an interface connecting the tubular extension to the flange. The tubular extension is sized and shaped to mate with the host pipe with which it is associated. Likewise, the flange is sized, shaped, and has an aperture pattern that corresponds with the fitting to which it will be attached. The dimensions the flange 10 can vary widely, depending on the application. Fittings and flanges of the present invention are preferably constructed of a substrate includes a plurality of carbon, aramid and thermoplastic fibers that are needle punched 34 together
The manufacturing of fittings/blind flanges from a substrate first requires that different sizes are created. Next, the substrate is compressed and heated sufficiently to take the shape of the mold. Finally, the substrate is cooled back to room temperature and then removed from the mold.
In use, a pipeline including a pipe segment having a compromised portion in need of repair is identified. The conventional fittings from the terminal ends of the host pipe are excised, with the host pipe itself staying substantially in position.
The excision of the conventional fittings provides access points through which uncured CIPP can be fed into host pipe. The CIPP is cured using a heater which forces superheated air at a specific pressure and for a specific duration. The result is the host pipe internally lined with cured CIPP, thereby forming a repaired portion. Ends of CIPP extending beyond the host pipe are subsequently cut and removed.
The fittings are positioned onto terminal ends of CIPP-enhanced host pipe, then cured. The result is a CIPP-enhanced host pipe with cured in place fittings that bolted to fittings of adjoining pipe segments. Gaskets are positioned between corresponding fittings thereby forming a substantially inseparable structure that is strong, flexible, and resilient to leakage and deterioration.
The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
The following structure numbers shall apply to the following structures among the various FIGS.:
Broadly, the present invention pertains to a fitting that is cured in situ, thereby fusing with surrounding cured in place pipe. The fitting is subsequently connected with an adjoining fitting, to connect two segments of pipe in a pipeline.
Fitting 10 of the present invention is depicted in
Fittings 10 and blind flanges 70 of the present invention are preferably constructed of substrate 31. Referring to
The proportion of carbon fibers in substrate 31 is approximately 10 to 60% by weight. The proportion of aramid fibers in substrate 31 is approximately 0 to 15% by weight. The preferred proportion of fibers in substrate 31 is approximately 40% carbon, 0% aramid, and 60% thermoplastic, by weight.
Fibers are needle punched 34 together by conventional methods in a directional format. However, other combinations are also suitable. Substrate 31 can be produced in a variety of thicknesses, typically approximately 1.5 mm-9.0 mm, as appropriate for the specific application.
The manufacturing of fittings/blind flanges from a substrate first requires that different sizes are created. Next, the substrate is compressed and heated sufficiently to take the shape of the mold. Finally, the substrate is cooled back to room temperature and then removed from the mold.
As shown in
As shown in
The finished product depicted in
Referring to
Specifications of certain structures and components of the present invention have been established in the process of developing and perfecting prototypes and working models. These specifications are set forth for purposes of describing an embodiment, and setting forth the best mode, but should not be construed as teaching the only possible embodiment. Rather, modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. It should be understood that all specifications, unless otherwise stated or contrary to common sense, are +/−10%, and that ranges of values set forth inherently include those values, as well as all increments between. Also it should be understood that “substantially” and the like should be construed to mean generally, but allowing for irregularities due to material or manufacturing differences, human variances, and so forth.
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